Method and blank for forming a multi-panel container

ABSTRACT

A method for forming a multi-panel, hollow container from a unitary blank of sheet material includes forming two spaced fold lines in each quadrant of the blank disposed on opposed sides of an imaginary diagonal line extending across the quadrant and folding the blank along the fold lines.

The following U.S. patents are known and are considered to berepresentative of the current state of the art: U.S. Pat. No. D442,862,issued May 29, 2001, U.S. Pat. No. D457,028, issued May 14, 2002, U.S.Pat. No. D459,652, issued Jul. 2, 2002, U.S. Pat. No. 6,027,819, issuedFeb. 22, 2000, U.S. Pat. No. 4,517,251, issued May 14, 1985, U.S. Pat.No. 4,001,964, issued Jan. 11, 1977, U.S. Pat. No. 3,730,818, issued May1, 1973, U.S. Pat. No. D303,500, issued Sep. 19, 1989, U.S. Pat. No.D264,184, issued May 4, 1982, U.S. Pat. No. D202,920, issued Nov. 16,1965, U.S. Pat. No. D438,105, issued Feb. 27, 2001, U.S. Pat. No.D360,824, issued Aug. 1, 1995, U.S. Pat. No. 4,917,291, issued Apr. 17,1990, U.S. Pat. No. 2,562,261, issued Jul. 31, 1951, U.S. Pat. No.727,723, issued May 12, 1903 and U.S. Pat. No. 4,227,640, issued Oct.14, 1980.

TECHNICAL FIELD

This invention relates to a method for forming a multi-panel containerhaving an enclosed, hollow interior. The invention also encompasses ablank utilized when forming a multi-panel container.

BACKGROUND OF THE INVENTION

As will be seen below, the present invention encompasses a unitary blankfor forming a multi-panel container. A method is also encompassed by thepresent invention.

Boxes and other containers are commonly formed from unitary or integralblanks and there are literally hundreds if not thousands of containers,boxes, etc. formed from a unitary blank or from a multi-component blank,the nature of the container being adapted for both general and specificuses. These containers range from very simple to complex and from plainto decorative.

The prior art indicated above does not teach or suggest the method andblank disclosed and claimed herein.

DISCLOSURE OF INVENTION

The method of this invention relates to formation of a multi-panelcontainer having an enclosed, hollow interior from a unitary blank ofsheet material of specialized construction. Utilizing the teachings ofthe present invention, a wide variety of decorative containers arereadily produced following a unique method and while utilizing a uniqueblank having certain structural features which can be varied andutilized to construct many different container configurations.

The method for forming a multi-panel container having an enclosed,hollow interior of the present invention includes the step of forming aunitary blank of sheet material having four blank outer edges, fourblank corners and four blank quadrants, the blank quadrants meeting at alocation on the blank spaced inwardly from the four blank sides.

In each blank quadrant, a double-ended, first fold line and adouble-ended second fold line are created. According to the method, bothends of the first and second fold lines are interconnected and the firstand second fold lines in each blank quadrant are spaced from one anotherbetween the connected ends thereof to define a side panel disposedcompletely within the blank quadrant.

The first and second fold lines in each blank quadrant are disposed onopposed sides of an imaginary diagonal line extending across the blankquadrant between opposed junctures formed by adjoining blank outer edgesat the blank quadrant boundary.

The side panels at least partially surround and define a bottom panel,the side panels and the adjoining blank outer edges defining top panels.

The unitary blank is folded along all of the first fold lines located inall four quadrants thereof whereby the side panels extend upwardly fromthe blank bottom panel. The unitary blank is then folded along all ofthe second fold lines located in all four quadrants thereof whereby thetop panels extend inwardly from the side panels over the bottom panel toenclose the hollow bottom interior.

Other features, advantages and objects of the present invention willbecome apparent with reference to the following description andaccompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a top, plan view of a square blank of sheet material,diagrammatically illustrating geometric features of the blank, includingimaginary quadrant defining lines and imaginary diagonal lines extendingacross each quadrant;

FIG. 2 is a view similar to FIG. 1, but illustrating fold lines formedin each quadrant;

FIG. 3 is a view similar to FIG. 2, but without a depiction of theimaginary quadrant defining lines and diagonal lines;

FIG. 4 is an enlarged perspective view of the blank of FIG. 3;

FIGS. 5-7 are perspective views illustrating consecutive stages in theformation of a container utilizing the method and blank of the presentinvention, FIG. 7 showing the fully assembled container;

FIG. 8 is a view similar to FIG. 2, but illustrating a second blankembodiment;

FIG. 9 is a view similar to FIG. 4, but illustrating the second blankembodiment;

FIG. 10 is a bottom, perspective view of the container formed from thesecond blank embodiment;

FIG. 11 is a top, perspective view of the assembled container formedfrom the blank of FIG. 8;

FIG. 12 is a side, elevational view of the assembled container formedfrom the blank of FIG. 8;

FIG. 13 is an elevational view of a third blank embodiment of theinvention;

FIG. 14 is a top, perspective view of the blank of FIG. 13;

FIG. 15 is a perspective view illustrating the blank of FIG. 13 beingconverted into a container;

FIG. 16 is a perspective view of the container formed from the thirdblank embodiment;

FIG. 17 is a top, plan view of a fourth blank embodiment;

FIG. 18 is a top, perspective view of the blank of FIG. 17;

FIG. 19 illustrates the blank of FIG. 17 being formed into a container;and

FIG. 20 illustrates a container made from the blank of FIG. 17.

MODES FOR CARRYING OUT THE INVENTION

Referring now to FIG. 1, a unitary blank of sheet material such aspaperboard, plastic or the like is designated by reference numeral 10.The blank has four blank outer edges, four blank corners and four blankquadrants outlined by intersecting imaginary lines 12 and 14 disposed atright angles to one another and extending completely across the blank.That is, the quadrants are defined by the blank outer edges and thequadrant lines 12, 14 which form the boundaries of the blank quadrants.Also shown in FIG. 1 are imaginary diagonal lines 16. Each diagonal line16 extends across a blank quadrant between opposed junctures formed byadjoining blank outer edges at the blank quadrant boundary. The blankquadrants meet at central location 18 on blank 10 spaced inwardly fromthe four blank sides.

Referring now to FIG. 2, in each blank quadrant, a double-ended firstfold line 20 and a double-ended second fold line 22 are created usingsuitable fabrication techniques such as scoring or perforating.

The first and second fold lines in each blank quadrant are spaced fromone another between the connected ends thereof to define a side panel 24disposed completely within the blank quadrant.

The first and second fold lines 20, 22 in each blank quadrant aredisposed on opposed sides of their associated imaginary diagonal line16. The side panels 24 in this embodiment extend the full lengths oftheir respective imaginary diagonal lines 16 and meet, as shown. Theside panels 24 are of identical configuration and are mirror images ofone another in adjoining quadrants. The connecting side panels 24surround and define a bottom panel 30. The side panels 24 and theadjoining blank outer edges define generally triangular-shaped toppanels 32.

Each of the first and second fold lines is curved over a portion of thelength thereof and straight over a portion of the length thereof. Thefirst and second fold lines are of the same length and are symmetricallydisposed relative to their respective imaginary diagonal lines, beingmirror images of one another.

FIGS. 5 and 6 show sequential steps carried out in the formation of acontainer from the blank 10. In FIG. 5 the integral blank 10 is shown inthe process of being folded about all of the first fold lines 20 locatedin all four quadrants whereby the side panels 24 will extend upwardlyfrom the blank bottom panel 30.

Next, the unitary blank is folded along all of the second fold lines 22as shown in FIG. 6 whereby the top panels 32 will extend inwardly fromthe side panels over the bottom panel to enclose the hollow bottominterior. FIG. 7 shows the completely folded unit. The top panels may besecured in position by any suitable expedient such as stickers oradhesive tape (not shown).

FIGS. 8-12 depict another embodiment of the invention. In this instance,a four sided blank 40 also has four quadrants meeting at a centrallocation on the blank. FIG. 8 shows imaginary diagonal lines 42extending across the quadrants. Disposed at opposite sides of eachimaginary diagonal line 42 is a first fold line 44 including twostraight first fold line segments and a second fold line 46 formed oftwo straight second fold line segments. The first fold lines 44 arelonger than the second fold lines 46. The first and second fold lines44, 46 define side panels 48.

Side panels 48 surround and define a bottom panel 50 of cruciformconfiguration. Top panels 52 are defined by the outer boundaries of thequadrants and second fold lines 46. Folding of the blank as depicted inFIG. 10 will result in formation of the container shown in FIGS. 11 and12.

FIGS. 13-16 illustrate another embodiment of the invention. In thisarrangement a blank 60 is changed from its flat state depicted in FIGS.13 and 14 to the configuration shown in FIG. 16. FIG. 15 illustrates theblank 60 in the process of being folded to form the container. In thisarrangement, the ends of first fold lines 62 and second fold lines 64terminate and connect at locations spaced inwardly from the boundariesof their respective quadrants. The cruciform bottom panel 66 is onlypartially surrounded by the side panels 68 formed by the first andsecond fold lines. Thus, the bottom panel extends to the outer edges ofthe blank and more particularly to recesses 70 formed in the four sidesof the blank. In this embodiment lock tabs 72 are utilized to secure thetop panels 74 together as shown in FIG. 16.

FIGS. 17-20 show a four sided blank 80 which is folded from the flatcondition illustrated in FIGS. 17 and 18 to form the box or containershown in FIG. 20. FIG. 19 shows an intermediate stage during formationof the container. In this embodiment the blank 80 is in the shape of arhomboid parallelogram. Also, there are two pairs of first fold lines—apair of first fold lines 82 and a pair of first fold lines 84, thelatter being shorter than the former. Likewise, there are two sets ofsecond fold lines, 86, 88, the latter being shorter than the former.This enables the blank, when folded, to form a generally rectangularshaped container having pointed corners as depicted in FIG. 20.Auxiliary fold lines 90 are formed in the blank between adjacent sidepanels 92, 94 to facilitate folding of the blank.

1. A method for forming a multi-panel container having an enclosed,hollow interior, said method comprising the steps of: forming a unitaryblank of sheet material having four blank outer edges, four blankcorners and four blank quadrants, said blank quadrants meeting at alocation on said blank spaced inwardly from said four blank sides; ineach blank quadrant, creating a double-ended first fold line and adouble-ended second fold line, both the ends of the first and secondfold lines being interconnected and said first and second fold lines ineach blank quadrant being spaced from one another between the connectedends thereof to define a side panel disposed completely within the blankquadrant, said first and second fold lines in each blank quadrant beingdisposed on opposed sides of an imaginary diagonal line extending acrossthe blank quadrant between opposed junctures formed by adjoining blankouter edges at the blank quadrant boundary, the side panels at leastpartially surrounding and defining a bottom panel, said side panels andsaid adjoining blank outer edges defining top panels; folding theunitary blank along all of the first fold lines located in all fourquadrants thereof whereby the side panels extend upwardly from saidblank bottom panel; and folding the unitary blank along all of thesecond fold lines located in all four quadrants thereof whereby the toppanels extend inwardly from said side panels over said bottom panel toenclose said hollow bottom interior.
 2. The method according to claim 1wherein the step of creating said double-ended first and second foldlines comprises creating double-ended first and second fold lines curvedover at least portions of the lengths thereof.
 3. The method accordingto claim 1 wherein the step of creating said double-ended first andsecond fold lines comprises creating double-ended first and second foldlines straight over at least portions of the lengths thereof.
 4. Themethod according to claim 1 including the additional step of sealingtogether said top panels after said top panels extend inwardly from saidside panels and over said hollow panel.
 5. The method according to claim1 wherein said first and second fold lines are shaped during creationthereof to define side panels of substantially identical configuration.6. The method according to claim 5 wherein said first and second foldlines are shaped during creation thereof to define side panels ofsubstantially identical configuration which are substantially mirrorimages of one another in adjoining quadrants.
 7. The method according toclaim 1 wherein said first and second fold lines are shaped duringcreation thereof so that they are asymmetrical in length and relative tothe imaginary diagonal line located therebetween.
 8. The methodaccording to claim 1 wherein said first and second fold lines are shapedduring creation thereof so that they differ in length.
 9. The methodaccording to claim 1 wherein said first and second fold lines are shapedduring creation thereof so that at least one of the ends thereof isspaced inwardly from the boundary of the quadrant with which it isassociated.
 10. The method according to claim 9 wherein said first andsecond fold lines are shaped during creation thereof so that both of theends thereof are spaced from the boundary of the quadrant with whichthey are associated.
 11. The method according to claim 1 wherein saidfirst and second fold lines are shaped during creation thereof to defineside panels extending the full length of said imaginary diagonal linewherein side panels of adjacent quadrants meet and completely surroundsaid bottom panel.
 12. The method according to claim 1 including theadditional step of forming auxiliary fold lines in said unitary blankbetween adjacent side panels.
 13. The method according to claim 1wherein said step of forming a unitary blank of sheet material comprisesforming a square blank.
 14. The method according to claim 1 wherein saidstep of forming a unitary blank of sheet material comprises forming aparallelogram-shaped blank.
 15. The method according to claim 14 whereinsaid step of forming a unitary blank of sheet material comprises forminga rhomboid parallelogram-shaped blank.
 16. A unitary blank of sheetmaterial for forming a multi-panel container having an enclosed, bottominterior, said blank having four blank outer edges, four blank corners,and four blank quadrants, said blank quadrants meeting at a location onsaid blank spaced inwardly from said four blank sides, each blankquadrant having a double-ended first fold line and a double-ended secondfold line, both ends of said first and second fold lines in each blankquadrant being connected and said first and second fold lines in eachblank quadrant being spaced from one another between the connected endsthereof and defining a side panel disposed completely within the blankquadrant, said first and second fold lines in each blank quadrant beingdisposed on opposed sides of an imaginary diagonal line extending acrossthe blank quadrant between opposed junctures formed by adjoining blankouter edges at the blank quadrant boundary, the side panels at leastpartially surrounding and defining a bottom panel, and said side panelsand said adjoining blank outer edges defining top panels.
 17. The blankaccording to claim 16 wherein said double-ended first and second foldlines are curved over at least portions of the lengths thereof.
 18. Theblank according to claim 16 wherein said double-ended first and secondfold lines are straight over at least portions of the lengths thereof.19. The blank according to claim 16 including securement means forsecuring together said top panels.
 20. The blank according to claim 16wherein said first and second fold lines define side panels ofsubstantially identical configuration.
 21. The blank according to claim20 wherein said side panels are substantially mirror images of oneanother in adjoining quadrants.
 22. The blank according to claim 16wherein said first and second fold lines are asymmetrical relative theimaginary diagonal line located therebetween.
 23. The blank according toclaim 16 wherein said first and second fold lines differ in length. 24.The blank according to claim 16 wherein at least one of the ends of eachof said first and second fold lines is spaced from the boundary of thequadrant with which the first and second fold lines are associated. 25.The blank according to claim 24 wherein both of the ends of both saidfirst and second fold lines are spaced from the boundary of the quadrantwith which the first and second fold lines are associated.
 26. The blankaccording to claim 16 wherein said side panels extend the full length ofthe imaginary line, and with side panels of adjacent quadrants meetingand completely surrounding the bottom panel.
 27. The blank according toclaim 16 wherein auxiliary fold lines are formed therein betweenadjacent side panels.
 28. The blank according to claim 16 in the shapeof a square.
 29. The blank according to claim 16 in the shape of aparallelogram.
 30. The blank according to claim 16 being in the shape ofa rhomboid parallelogram.